Float valve assembly for a water purification system

Abstract

An improved float valve assembly is provided for regulating water inflow to a purification module of a water purification system, such as a reverse osmosis purification module or the like. The float valve assembly is mounted within a reservoir for receiving and storing relatively purified water produced by the purification module, and includes a valve unit defining a vertically extending flow path from a tap water source to the purification module. A primary float carried on a float arm responds to rising and falling water level within the reservoir for respectively closing and opening a primary banjo valve mounted along the flow path. An over-center switch provides snap-action closure of the primary valve in response to rising water level, and the primary float is mounted on the float arm for a limited range of lost motion to accommodate this snap-action valve closure. A secondary banjo valve is mounted along the flow path at a location above the primary valve, and, in the event of primary valve malfunction, is closed by a secondary float carried on a float arm and responsive to rising reservoir water level. In a preferred form, the secondary valve remains closed upon subsequent descent of the water level, and is manually re-opened by depression of a reset button.

What is claimed is: 
     
       1. A float valve assembly for regulating water inflow to a water purification system having a purification module and a reservoir for storing produced purified water, said float valve assembly comprising: a valve unit including a housing defining a flow path having an inlet adapted for connection to a water source and an outlet adapted for connection to a purification module, and a primary valve mounted along said flow path, said primary valve being movable between open and closed positions respectively permitting and preventing water flow through said flow path to the purification module;   an elongated float arm having one end coupled to said primary valve;   a primary float;   means for connecting said primary float generally to an opposite end of said float arm to permit a limited range of vertical lost motion therebetween;   said primary float being responsive to the level of water within a reservoir for lifting said float arm for moving said primary valve from said open position toward said closed position when the water level rises to a first predetermined level, and for lowering said float arm for moving said primary valve from said closed position toward said open position when the water level falls below said first predetermined level; and   switch means responsive to the water level rising within the reservoir substantially to said first predetermined level for positively displacing said float arm to move said primary valve to said closed position substantially with a snap action, said opposite end of said float arm being substantially free to displace vertically upwardly relative to said primary float within said limited range of lost motion upon snap action movement of said primary valve to said closed position.   
     
     
       2. The float valve assembly of claim 1 wherein said switch means comprises an over-center switch. 
     
     
       3. The float valve assembly of claim 1 wherein said switch means comprises a magnetic switch unit including a first magnet carried by said float arm for displacement in close proximity with at least one second magnet, said first and second magnets being oriented with like poles presented toward each other to generate magnetic repulsion forces resisting on-center alignment of said first and second magnets, said primary float lifting said float arm to displace said first magnet toward on-center alignment with said second magnet in response to rising water level within the reservoir, said primary float lifting said float arm with a sufficient force when the water level rises substantially to said first predetermined level to displace said first magnet over-center relative to said second magnet and to move said primary valve positively to said closed position. 
     
     
       4. The float valve assembly of claim 3 wherein said at least one second magnet is mounted in a fixed position relative to said first float arm. 
     
     
       5. The float valve assembly of claim 3 wherein said at least one second magnet comprises a pair of magnets mounted on opposite sides of said first magnet on said float arm. 
     
     
       6. The float valve assembly of claim 1 wherein said connecting means comprises a shoulder screw having one end threadably connected to said primary float and further including an unthreaded slide shank portion adjacent an enlarged head, said opposite end of said float arm being connected slidably along said unthreaded shank portion of said shoulder screw, whereby the length of said unthreaded shank portion defines the length of said limited range of lost motion. 
     
     
       7. The float valve assembly of claim 1 further including a weight mounted on a lower end of said primary float, said weight having a substantially neutral buoyancy in water. 
     
     
       8. The float valve assembly of claim 3 wherein said primary float applies a downward force to said float arm in response to a falling water level within the reservoir to move said first magnet downwardly and over center relative to said second magnet to re-open said primary valve. 
     
     
       9. The float valve assembly of claim 1 wherein said valve unit further includes a secondary valve mounted along said flow path and movable between open and closed positions respectively permitting and preventing water flow through said flow path to the purification module, and a secondary float coupled to said secondary valve and responsive to the level of water within the reservoir for moving said secondary valve from said open position to said closed position when the water level rises to a second predetermined level higher than said first level, and for allowing movement of said secondary valve from said closed position to said open position when the water level falls below said second predetermined level. 
     
     
       10. The float valve assembly of claim 1 wherein said valve unit is mounted within the reservoir. 
     
     
       11. The float valve assembly of claim 1 wherein said flow path is vertically oriented. 
     
     
       12. A float valve assembly for regulating water inflow to a water purification system having a purification module and a reservoir for storing produced purified water, said float valve assembly comprising: a valve unit including a housing defining a flow path having an inlet adapted for connection to a water source and an outlet adapted for connection to a purification module, and a primary valve mounted along said flow path, said primary valve being movable between open and closed positions respectively permitting and preventing water flow through said flow path to the purification module;   an elongated float arm having one end coupled to said primary valve;   a primary float;   means for connecting said primary float generally to an opposite end of said float arm to permit a limited range of vertical lost motion therebetween;   said primary float being responsive to the level of water within a reservoir for lifting said float arm for moving said primary valve from said open position toward said closed position when the water level rises to a first predetermined level, and for lowering said float arm for moving said primary valve from said closed position toward said open position when the water level falls below said first predetermined level; and   switch means responsive to the water level rising within the reservoir substantially to said first predetermined level for positively displacing said float arm to move said primary valve to said closed position;   said switch means comprising a magnetic switch unit including a first magnet carried by said float arm for vertical displacement in close proximity with at least one second magnet, said first and second magnets being oriented with like poles presented toward each other to generate magnetic repulsion forces resisting on-center alignment of said first and second magnets, said primary float lifting said float arm to displace said first magnet toward on-center alignment with said second magnet in response to rising water level within the reservoir, said primary float lifting said float arm with a sufficient force when the water level rises substantially to said first predetermined level to displace said first magnet over-center relative to said second magnet substantially with a snap action to move said primary valve positively to said closed position, said opposite end of said float arm being substantially free to displace vertically upwardly relative to said primary float within said limited range of lost motion upon said snap action movement of said primary valve to said closed position.   
     
     
       13. The float valve assembly of claim 12 wherein said connecting means comprises a shoulder screw having one end threadably connected to said primary float and further including an unthreaded slide shank portion adjacent an enlarged head, said opposite end of said float arm being connected slidably along said unthreaded shank portion of said shoulder screw, whereby the length of said unthreaded shank portion defines the length of said limited range of lost motion. 
     
     
       14. The float valve assembly of claim 12 further including a weight mounted on a lower end of said primary float, said weight having a substantially neutral buoyancy in water. 
     
     
       15. The float valve assembly of claim 12 wherein said primary float applies a downward force to said float arm in response to a falling water level within the reservoir to move said first magnet downwardly and over center relative to said second magnet to re-open said primary valve. 
     
     
       16. The float valve assembly of claim 12 wherein said at least one second magnet is mounted in a fixed position relative to said float arm. 
     
     
       17. The float valve assembly of claim 12 wherein said at least one second magnet comprises a pair of magnets mounted on opposite sides of said first magnet on said float arm. 
     
     
       18. The float valve assembly of claim 12 wherein said valve unit further includes a secondary valve mounted along said flow path and movable between open and closed positions respectively permitting and preventing water flow through said flow path to the purification module, and a secondary float coupled to said secondary valve and responsive to the level of water within the reservoir for moving said secondary valve from said open position to said closed position when the water level rises to a second predetermined level higher than said first level, and for allowing movement of said secondary valve from said closed position to said open position when the water level falls below said second predetermined level. 
     
     
       19. The float valve assembly of claim 12 wherein said valve unit is mounted within the reservoir. 
     
     
       20. The float valve assembly of claim 12 wherein said flow path is vertically oriented. 
     
     
       21. A float valve assembly for regulating water inflow to a reservoir, said float valve assembly comprising: a valve unit including a housing defining a flow path having an inlet adapted for connection to a water source and an outlet adapted for connection in flow communication to a reservoir, and a primary valve mounted along said flow path, said primary valve being movable between open and closed positions respectively permitting and preventing water flow through said flow path to the purification module;   an elongated float arm having one end coupled to said primary valve;   a primary float;   means for connecting said primary float generally to an opposite end of said float arm to permit a limited range of vertical lost motion therebetween;   said primary float being responsive to the level of water within a reservoir for lifting said float arm for moving said primary valve from said open position toward said closed position when the water level rises to a first predetermined level, and for lowering said float for moving said primary valve from said closed position toward said open position when the water level falls below said first predetermined level; and   switch means responsive to the water level rising within the reservoir substantially to said first predetermined level for positively displacing said float arm to move said primary valve to said closed position substantially with a snap action, said opposite end of said float arm being substantially free to displace vertically upwardly relative to said primary float within said limited range of lost motion upon snap action movement of said primary valve to said closed position.   
     
     
       22. The float valve assembly of claim 21 wherein said switch means comprises an over-center switch. 
     
     
       23. The float valve assembly of claim 21 wherein switch means comprises a magnetic switch unit including a first magnet carried by said float arm for displacement in close proximity with at least one second magnet, said first and second magnets being oriented with like poles presented toward each other to generate magnetic repulsion forces resisting on-center alignment of said first and second magnets, said primary float lifting said float arm to displace said first magnet toward on-center alignment with said second magnet in response to rising water level within the reservoir, said primary float lifting said float arm with a sufficient force when the water level rises substantially to said first predetermined level to displace said first magnet over-center relative to said second magnet and to move said primary valve positively to said closed position. 
     
     
       24. The float valve assembly of claim 23 wherein said at least one second magnet is mounted in a fixed position relative to said float arm. 
     
     
       25. The float valve assembly of claim 23 wherein said primary float applies a downward force to said float arm in response to a falling water level within the reservoir to move said first magnet downwardly and over center relative to said second magnet to re-open said primary valve.